Laminated non-woven sheet

ABSTRACT

A LAMINATED NON-WOVEN SHEET IS MADE FROM NON-WOVEN MATS OF MELT-BROWN THERMOPLASTIC POLYMER FIBERS. THE NON-WOVEN SHEETS MAY BE PRODUCED BY EITHER POINT WELDING OR USING ADHESIVES TO LAMINATE AT LEAST ONE NON-WOVEN MAT HAVING A HIGH STRIP TENSILE STRENGTH TO AT LEAST ON   NON-WOVEN MAT HAVING A HIGH TEAR RESISTANCE SO THAT THE SHEETS HAVE BOTH HIGH STRIP TENSILE STRENGTH AND HIGH TEAR RESISTANCE.   D R A W I N G

March 5, 1974 J. s. FRENTICE 3,795,571

LAMINATED NON-WOVEN SHEET Original Filed Oct. 9, 1969 FIG.I

i l8 l9 7 PAPER '7 mwnmq MATS 7 l2 PAPER 5 X 23 sums T\ SPACER BLOCK United States Patent O 3,795,571 LAMINATED NON-WOVEN SHEET James S. Prentice, Baytown, Tex, assignor to Esso Research and Engineering Company Original application Oct. 9, 1969, Ser. No. 864,994, now

Patent No. 3,715,251. Divided and this application Sept. 21, 1972, Ser. No. 291,127

Int. Cl. 1332b 7/14; D0411 11/.00

US. Cl. 161148 10 Claims ABSTRACT OF THE DISOLOSURE A laminated non-woven sheet is made from non-woven mats of melt-blown thermoplastic polymer fibers. The non-woven sheets may be produced by either point welding or using adhesives to laminate at least one non-woven mat having a high strip tensile strength toat least one non-woven mat having a high tear resistance so that the sheets have both high strip tensile strength and high tear resistance.

This is a division, of application Ser. No. 864,994, filed Oct. 9, 1969, now Pat. No. 3,715.251.

BACKGROUND OF THE INVENTION (1) Field of the invention The present invention is directed to laminating a plurality of non-woven mats ofmelt-blown thermoplastic polymer fibers to produce a non-woven sheet. The non-woven sheets may be produced by either point welding or using adhesives.

(2) Prior art US. 3,341,394; British Pat. 1,055,187.

SUMMARY OF THE INVENTION BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic view of the overall melt-blowing process;

FIG. 2 is a detailed view in longitudinal cross-section of a die which may be used in the melt-blowing process;

FIG. 3 is a schematic view of a press used in fuse-bonding a non-Woven mat or point welding two mats together;

FIG. 3A is a schematic view of calendar rolls which may be used instead of a press; and

FIG. 4 is a schematic view of a laminated non-woven sheet according to the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS eferring to FIG. 1 of the drawings, a thermoplastic polymer is introduced into a pellet hopper 1 of an extruder 2. The thermoplastic polymer is forced through the extruder 2 into a die head 3 by a drive 4. The die head 3 may contain heating plates 5 which may control the temperature in the die head 3. The thermoplastic polymer is then forced out of a row of die openings 6 in the die head 3 into a gas stream which attenuates the thermoplastic polymer into fibers 7 which are collected on 3,795,571 Patented Mar. 5, 1974 ice a moving collecting device 8 such as a drum 9 to form a continuous mat 10. The gas stream which attenuates the thermoplastic polymer is supplied through gas jets 11 and 12 respectively, which are seen more clearly in FIG. 2. The gas slots 11 and 12 are supplied with a hot gas, preferably air, by gas lines 13 and 14, respectively.

The process may be further understood by considering the details of the die head 3 which is more fully set forth in FIG. 2. The die head 3- is made up of upper die plate 15 and a lower die plate 16. The thermoplastic polymer is introduced in the back of the die plates 15 and 16 through an inlet 17 as it is forced through the extruder 2 into the back of the die head 3. The thermoplastic polymer then goes into a chamber 18 between the upper and lower die plates 15 and 16, respectively. The facing of the die plate 16 may have milled grooves 19 which terminate in the die openings 6. It is understood, of course, that the milled grooves may be in the lower die plate 16, in the upper die plate 15, or that grooves may be milled in both plates 15 and 16. Still further, if a single plate is used in place of the upper and lower die plates, the grooves may be drilled to produce the die openings 6. An upper gas cover plate 20 and a lower gas cover plate 21 are connected to the upper die plate and lower die plate 15 and 16 respectively to provide an upper air chamber 22 and a lower air chamber 23 which terminate in the gas slots 11 and 12 respectively. The hot gas is supplied through inlet 24 in upper gas cover plate 20 and inlet 25 in lower gas cover plate 21. Suitable baffling means (not shown) may be provided in both the upper air chamber 22 and lower air chamber 23 to provide a uniform flow of air through the gas slots 11 and 12 respectively. The die head 3 may contain heating means 5 for heating both the thermoplastic polymer and air in the die head 3'.

The characteristics of the non-woven thermoplastic polymer mats produced by the melt-blowing process will vary considerably depending upon the particular process conditions used. The characteristics of the non-woven thermoplastic polymer mats are affected in large part by the air flow rates used in the melt-blowing process and the distance of the take-up device from the die openings in the die head. These effects were noted as melt-blown non-woven mats were attempted to be made having high strip tensile strength and high tear resistance. However, both high strip tensile strength and high tear resistance were found to be unobtainable in a single melt-blown non-woven thermoplastic polymer mat. Inherent in the present invention is the recognition that to obtain both high strip tensile strength and high tear resistance in a nonwoven thermoplastic polymer sheet, mats have to be laminated one to another. Specifically, this invention involves laminating mats having a high strip tensile strength mats having a high tear resistance.

In the melt-blowing process, when the air rates are high and the pounds of air to pounds of thermoplastic polymer extruded through the die head are high (suitably greater than about 140, desirably 150, and preferably in excess of 200 lbs. air/lbs. of polymer for polypropylene) the thermoplastic polymer fibers in the non-woven mat are such that generally the mat has a higher zero span tensile strength. The fibers at the higher air rates appear to be drawn, and are much finer fibers as evidenced by their small diameters, which range from 1 to 10 microns.

One of the other process variables in the melt-blowing process which materially affects the characteristics of the non-Woven thermoplastic polymer mat is the distance of the take-up device from the die openings and the die head. When the collecting device is between 1 to 6 inches from the die openings, there is evidence of considerable self-bonding of the fibers as they are laid down in the nonwoven mat. At distances greater than 6 inches between the die'openings and collector device, some self-bonding still occurs but the amount of self-bonding decreases with distance. The term self-bonding herein means thermal bonding of one fiber to another in the melt-blowing process as the non-woven thermoplastic-polymer mats are formed. The strip tensile strength of the thermoplastic polymer mats asrproduced by the melt-blowing process is greatest in those mats having the highest degree of self- :bonding, where as the self-bonding decreases, the mat is comprised essentially of entangled fibers and the strip tensile strength materially decreases. Another factor in the strip tensile strength of the melt-blown mat is the tensile strength of the fiber itself. The tensile strength of the fibers in the melt-blown non-woven mat are found by measuring the zero span tensile strengths of the mats, a measurement which utilizes the same general procedure employed to obtain the strip tensile strength of the mats. The procedure for obtaining strip tensile strength and zero span tensile strength are those in ASTM procedure -D+,828-60, with the exception that to measure the strip tensile strength the clamps are set apart at a distance of 2 inches using an elongation rate of 250% /min., but to measure the zero span tensile strength, the clamps are not separated by any distance. In both instances, the results are reported in meters, the unit resulting when the force necessary to break the mat, measured in grams, is divided by the width of the sample, measured in meters, all of which is divided by the basis weight of the sample in terms of grams/meter The process variables used in the melt-blowing process to obtain mats of high strip tensile strength result in low tear resistances in those mats. Correspondingly, when a non-woven mat of high tear resistance is produced, the mat has a low strip tensile strength. The conditions for producing a mat of high tear resistance generally require that the take-up device be positioned at a distance greater than '8 inches from the die openings so that substantial entanglement of the fibers occur rather than a large degree of self-bonding. Furthermore, it is desirable to operate at lower air rates and, accordingly, much lower 'air to polymer rates (generally less than about 50 for polypropylcue), to obtain a mat in which the fibers are of a larger diameter-within the range of to 40 microns, usually to microns. The non-woven mats made of these larger diameter thermoplastic polymer fibers, collected as entangled fibers and containing some self-bonding, have higher tear resistances than the non-Woven mats made of interentangled smaller diameter fibers. The tear resistance ofthe non-woven mat is measured by a standard Elmendorf tear strength tester in accordance WithASTM procedure D689-62.

For use in the laminated sheet of the present invention,

the strip tensile strengths of the non-woven mats that are formed by the melt-blowing process are generally lower 'heat' to the mat to melt discrete portions of the mat and fuse a portion of the fibers in' the mat. Alternatively, the fuse-bonding may be effected by a general fusion of the fibers by applying an unbroken pattern of heat to the mat. In thefuse-bonding process, sufficient pressure is applied to prevent shrinkage of the fibers in the non-woven mat as indicated by measuring the size of the mat before and after fuse-bonding and as determined by a lack of decrease in the zero span tensile strength of the non-woven mat.

Referring to FIG. 3, a heated press may be used in the fusebonding process to increase the strip tensile strengths of the melt-blown non-woven mats. The press 30 comprises a plate 31 and a plate 32. The plate 31 has a plurality of spaced apart projections 33 which terminate in flat lands 34 that are spaced in a design or pattern. The. spacing of a the projections 33, the total surface of the flat lands 34 and the pattern of the projections 33 of the plate 31 will partially determine the degree to which the fibers or the non-Woven mats are point bonded. The spacing of the projections 33 and the pattern may vary greatly although suitable patterns are rectilinear or diagonal grids. Suitable spacing for the projections 33 are between about A inch and A inch. The depth to which the projections 33'will penetrate the non-woven sheet'may be controlled by the use of spacers or shims placed between plate 31 and plate 32. The plate 32 may have a fiat surface which. would come in contact with the lands 34 of the projections 33 of plate 31 or the plate 32 may also have injections which are aligned with the projections of plate 31 so that the lands of the projections of plate 32 would contact the lands 34 0f the projections of plate 31. To obtain higher increases in the strip tensile strengths'of the non-woven mats, the deeper penetration of the projections 33 into the non-woven mats is desired. Each of the plates 31 and 32 may be heated independently so that the temperatures of the plates are not necessarily the same.

In the fuse-bonding process of the non-woven mats, it is convenient to use spacer sheets between the nonwoven mats and the plates 31 and 32, of the press to prevent the non-woven mat from sticking to the plates either during or subsequent to the fuse-bonding operation. Suitable spacer sheet material which may be employed include insulating materials such as tissue paper, ordinary paper and the like or heat conducting materials such as aluminum foil and the like. The conducting spacer sheets are preferred since the additional heat increases the fusing of the fibers in the fuse-bonding process.

For the'continuous production of the non-woven mats of improved higher strip tensile strengths, it is advantageous to carry out the fuse-bonding process by calendering the non-Woven mats under heating conditions which efifect fiber-to-fiber fusion under pressure sufiicient to prevent shrinkage of the fibers of the non-woven mat. Referring to FIG. 3A, calender rolls 40 and 41 are shown which may be employed instead of the press 30. The calender roll 40 may have projections which terminate in flat lands which may be patterned in a wide variety of forms, such as a diagonal grid (not shown). In the calendering operation to carry out the fuse-bonding, spacer sheets may also be used to prevent the non-woven mats from sticking to the calender rolls.

According to the present invention, a non-woven laminated sheet is produced from at least one mat of thermoplastic polymer fibers having a high strip tensile strength and at least one mat of the same thermoplastic polymer fiber having a high tear resistance, so that the laminated sheet has both a high strip tensile strength and high tear resistance. The lamination may be accomplished by using an adhesive or by a point-welding process. The lamination is carried out to an extent that the melt-blown nonwoven mat having the high strip tensile strength and the melt-blown nonwoven mat having the high tear resistance each contribute their propertiesv to the non-woven laminated sheet in the approximate proportion of the weight fractions of each of the melt-blown non-woven mats.

The use of an adhesive to accomplish the'lamination is preferred when a non-woven laminated sheet having low delamination characteristics is desired. Suitable adhesives for laminating one melt-blown non-woven mat to another are such contact cements as the nitrile, SBR or polyisobutylene rubber types. lWhen using an adhesive, usually the adhesive is applied to one surface of one of the melt-blown non-Woven mats, the other mat is then placed in contact with the adhesive coating, and the mats are pressed together. Of course, the adhesive may be applied to surfaces of each of the melt-blown non-woven mats and the. coated surfaces placed in contact with one another for accomplishing the lamination. After the non-woven mats are coated with the adhesive and the mats are contacted one with the other, they may be passed through a plain surfaced calender roll to compress them together to form the non-woven laminated sheet of the present invention.

An alternative method of laminating the melt-blown the present invention and utilize the non-woven mats of melt-blown polypropylene fibers produced in accordance with the conditions set forth in Table I, which follows. The melt-blowing process used is that which was illustrated in FIGS. 1 and 2 of the drawings with the specific non-woven mats to form the non-woven laminated sheets 5 operating conditions as set forth in Table I. The specific of the present invention is to point weld the mats tonon-woven mat characteristics are also set forth in Table gether. The point-welding process is essentially the same I as to basis weight, zero span tensile strength and the as the process for fuse-bonding a single mat except that degree of uniformity of the mat in terms of the zero span in the point-welding process there are at least two mats tensile strength by the ratio of the cross direction to present, at least one melt-blown non-woven mat having a machine direction (CD/ MD).

TABLE I Mat Nos A B C D E F G H I J K L M N 0 P Q Polypropylene MFR 0.0 0.0 0 0.0 30 30 30 0.0 0.0 0.0 0.0 0.0 0.0 3.5 3.5 33.0 33.0 Extruder temperature F.) 092 053 702 720 700 090 085 042 040 091 091 090 090 047 050 580 585 Die temperature 0 F.) 037 030 043 042 035 031 530 010 000 034 031 033 032 009 002 533 525 P0lymerrate(g./min.) 8.4 8.0 8.0 8.0 8.1 8.1 8.1 8.2 8.2 8.4 8.4 8.4 8.4 7.0 7.0 8.0 8.5 Air flow (lbs/min.) 4.30 3.85 3.78 4.24 4.00 4.05 3.90 4.2 4.2 4.30 4.32 4.18 4.15 3.35 3.30 0.07 0.82 Lb air/1b peiymer 23 218 214 240 227 227 218 233 233 235 233 220 224 217 218 38 44 Screen distance (in. 4.0 0.0 0.0 0.0 4.0 4.0 4.0 4.0 4.0 3.0 0.0 8.0 12.0 4.0 4.0 18.0 12.0 Mat characteristics:

Basis weight (gJmfi)- 50 58 58 00 50 47 48 70 50 59 51 54 50 131 70 71 35 Zero spantensile 0,130 4,580 0,440 5,340 5,230 5,920 5,040 ,000 5,490 5,830 4,320 4,730

(JD/MD 0.04 0.57 0.02 0.70 0.07 0.01 0.02 0. 5 0.59 0.78 0.80

high strip tensile strength and at least one other melt- EXAMPLES l-l5 f non-Woven mat havlng a F reslstance' Laminated non-woven sheets of the present invention fernng to G 5 h nOmWovefn laminated sheet of the are illustrated by the examples set forth in Table II herepresent invention is illustrated with two mats point-welded inafter' The laminated Sheets are prepared by the lamina together: the non-woven mat A, having a high strip tention of a mewblown nomwoven mat of polypropylene Slle $ttengtt 1, and the other mat fibers having high strip tensile strength to a melt-blown having a high tear resistance. The point-welding process nomwoven mat of polypropylena fibers having high teal. be aeeomphshed elther by usulg Press l as resistance. The lamination is carried out either by pointlnustrated In by Q Q The.1ammanon welding the mats together (Examples 1-12) or by using of the sheets is accomplished in the point-welding process an adhesive (Examples by fusing fibers in each of the melt-blown mats at the The norkwoven mats of polypropylene fibers halving interface of the Supenmposed P shlnfs Spacers (not high strip tensile strength are prepared either by pointshown) may be used to permit the pro ections of either bonding (Examples or by calendaring (Examplas h Press h calender rolls to penetrate to a depth 10-15) under conditions as set forth in Table II. The permitting fusion of the fibers at the interface of the point bonding or calendaring is carried out on a 110m melt-blown e matswoven mat, identified by a capital letter, which was made In the point-welding process, the melt-bl w under the conditions of Table I. The non-woven mats Woven that B e t the h1g1} tear reslstallce 15 most after being treated to obtain the high strip tensile strength j to Change 111 Its Propertles by a heatlflg of were then laminated to melt-blown non-woven mats havwoven mat to high temperatures. Accordingly, it is preing high tear resistance (Mats P and Q of Table I). The ferred that the no that B havtng t e hlgh tear resulting laminated non-woven sheet properties are also resistance be placed in contact with the PIOJCCUOIIS of the set f th in Table 11. press or calender rolls instead of in contact with the fiat In Examples 1 9 the 1 b1 nomwoven mats PteSS Plate Calender T011, and that the temperature of (Mats A-D of Table I) have the strip tensile strength the plate of the press or the calender rolls having the i d b f -bo di i i i a prgss wherein the Projections be Operated at lower temperatures than the temperatures of the plates of the press are separately confiat PfeSS Plate 0t calender n the Point-Welding trolled. The temperatures of the plates are set forth in Process, Spacer Sheets y be used d in this Operation Table II, the upper plate being a smooth surfaced plate the spacer sheets which prevent the sticking of the nond th lower plate h i projections arranged i a woven mat to the press plate or calender rolls may be spaced tt I E l 1 4 th nomwoven mats either the same or di f er t materials- Accordingly, a 55 produced in accordance with the conditions in Table I heat insulating material Such as a Paper tissue P p were fuse-bonded to improve the strip tensile strengths may be used in contact with the high tear resistance f th t b using two spacer Sheets of tissue paper non-woven mat B, whereas the spacer sheet between the tween the non-woven mat and the plate having the pro- I10I1-W0ven met A having a high Strip tensile Strength jections and one spacer sheet of aluminum foil between may be a conducting material such as aluminum foil. th nomwoven mat d th smooth f d l t f These variations are pointed out merely to emphasize that a press, I Example 5 a pacer h t f l i foil the physical properties of the melt-blown non-woven mats w l d on h id of th o -wov t in the areattempted to be preserved at a high level in the lamifuse-bonding Ex l 6-9 a i i spacer h t f nation process. aluminum foil was used between the non-woven mat and The present invention is illustrated with non-woven h th surfaced plate f h press nd a single Spacer mats formed of melt-blown polypropylene fi s- H W- sheet of tissue paper was used between the non-woven ever, other thermoplastic polymer fibers may be used in mat and the, plate having projections, In each of Examples the Present invention and include other Polyolefins Su 1-9 the fuse-bonding was carried out for 10 seconds with as polyethylene; polyesters, including poly(methylmeththe plates being closed so that there was a spacing of ts and p y( y terephthalatel; p s/ des 0.005 inch between the lands of the projections and the such as poly(hexamethylene adipamide), poly (w-caprosmooth surfaced plate. The spacing is provided by a amide) and poly(hexaniethylene sebacamide); polyvinyls 0.005 inch shim between the plates. such as polystyrene; and other polymers such as polytri- The non-Woven mats (Mats E-I of Table I) in Examfluorochloroethylene. The specific melt-blown non-woven ples 10-15 are calendered to improve the high strip mats used in the examples which follow are illustrative of 7 tensile strength of the mats. The non-woven mats are pressed through heated calendering rolls at a rate of 20 mats making up the laminate, and this is the preferred feet per minute under a roller pressure of 700 p.l.i. at way. to form the laminated non-Woven sheets,-especially calender roll temperatures as set forth in Table II. when a high peel, strength or resistance to delamination -In Examples 1-12 the laminated non-woven sheet was is desired. The point-welded laminated non-woven sheets made by the point-welding process. The same press was had a very low peel strength of about 0.5 lb./inch. and employed in the point-welding process as was used to were embossed with the imprint of the plate. On the other accomplish the fusebonding of a single non-woven mat hand, the adhesive laminates had smooth surfaces and a to improve strip tensile strength. The temperatures of very high peel strength; thehigh tearlayer yielded betllie plates 51f the press are set forth in Table II. In Examfore delamination of the layers occurred. p es 1-4 e hig strip tensile strength mat was placed on the lower plate and the high tear resistance mat was EXAMPLES 16-20 contacted by the upper plate. Tissue paper was used as In these examples Examples l6-20 illustrate the th spacer sheet i ll in t I E l 5 12 h verse relationship between strip tensile strength and tear high tear resistance mat was placed on the lower plate resistance which is obtained in melt-blown non-woven and t e upp r plate contacted the high strip tensile mats. The strip tensile strengths and'tear resistances were strength mat. Again, tissue paper was used as the spacer measured for five non-Woven mats that were made by sheets. In each of Examples 1-12 the point welding was melt-blowing P yp p under essentially identical carried out for 10 seconds. In examples 1-6, the plates conditions Table except'that the dle'to'collficmr were closed to a spacing of 0,005 inch; in Examples 7 9, distance D-C-D) was varied. The results are presented in a spacing of 0.006; and in Examples 10-12, a spacing Table of 0.008 inch, between the smooth surfaced plate and the TABLE III lands of the projections of the other plate. The spacings were accomplished by the use of shims. Example number 16 17 18 19 20 In Examples 13-15 an adhesive was used to form th ats-u m- J A K L M 1 t d h t A 1 b l D-C-D (111') 3.0 4.0 6.0 8.0 12.0 amma e non-woven szee po yiso uty ene rubber giro stp n g 33 i s2 'i contact c en 0. p ensi 8 em t BW 3R4 7568.OA manufactured by Tear resistance (dmfi) 62 103 212 261 409 Polymer Industries, Inc. of Springdale, Conn, was apphed to Opposed Surfaces of hlgh tenslle While improved strip tensile strength was obtained in Strength mat 01' the hlgh tfial'v I'CSlStanCe mat and the the as made me1t-b1own non.woven mat using a hort pp Surfaces Were contacted t0 adhere the iWO mats 30 die-to-collector distance (Example 16), the tear resistance 9 anotherof this non-woven mat is extremely low, and conversely, The results of Examples 1-15 are presented in Table as the tear resistance was .improved (Example 20), the strip tensile strength became extremely low.

TABLE II Example number 1 2 3 4 5 6 7 8 Improve strip tensile strength:

Mats A- B C- D A..- B B 0. Press plate temperatures:

Upper F.) 285 292 297 297 205 300. Lower F.) ans 30s 2% 288 2% 290. Lamination conditions:

Mats A p1us,P.- B plus P--. 0 plus P..- D plus I--- A plus P--. B plus P--- B plus P-.- 0 plus P. Point-welding press temperatures:

Upper F.) 245 248 260 280 275 303 300 300. Lower F.) 285 287 27s 27% 245 227 23o 231. Laminated sheet properties:

Tensile (m.) 3,789 4,219 3,985- 3,928- 4,050- 4,160- 4,077- 5,125. Tear resistance (dmfl) 714 562 421 773. 597- 57a 86 463.

Example number 9 10 11 12 13 14 15 Improve strip tensile strength:

Mats (3.. E. F. G- H I H. Calender roll temperatures:

Upper F.) 298. 300 305 r 30% an? 30% 310. Lower F.) I 288 250 250 250 250 250 255. Lamination conditions:

Mats 0' plus P--. E plus P F plus P- G plus P-.. 11' plus 1 1' plus P"..- H plus Q. Point-welding press temperatures:

Upper F.) 301. 278 280 275 Lower F.) 230 225-. 240 240 Laminated sheet properties:

Tensile 111.) 4,794 4,268--- 4,218. r 4,474- 4,685- 5,061- 5,109. Tear resistance (dmfi) 584 796 641 93 952 513 903.

Prime indicates non-woven mat after treatment to improve strip tensile strength as indicated in specific example.

"Mat calendered three times at indicated temperatures. Mat Q calendered at room temperature, 700 p.l.i., 20 ttJmin.

Table II shows that laminated non-woven sheets having EXAMPLE 21 both a high strip tensile strength and a high tear resistance are made from a high strip tensile strength melt-blown This example illustrates how the strip tensile strength non-woven mat and a high tear resistant melt-blown nonof a non-woven mat is increased by fuse-bonding the mat. woven, mat. The non-woven sheets may be produced hav- Samples of non-woven mat I, made under melt-blowing ing strip tensile strengths exceeding 4000 meters and tear conditions which produce fibers that have a diameter from resistances in excess of 400. dm. The highest tear reabout 1 to 10 microns (see Table I), were calendered sistances and strip tensile strengths were attained in the once at heatedcalender roll temperatures ranging from laminated non-woven sheets when calendering was used 200 F. to 320 F. undera roller-pressure of 700 p.l.i. at to impart high strip tensile strength to a melt-blown nona line speed of 20 feet/minute, using the calender rolls of Woven mat and when an adhesive Wasused to unite the Examples 10%14. The results are tabulated in Table IV.

TABLE IV 7 Example 21 Calender roll temperatures:

Upper F. 70 200 225 250 275 287 300 310 230 Lower F. 70 147 165 185 205 206 220 230 240 Fuse-bonded mat properties:

Stn'p ten 10 (111.) 2, 346 2, 250 2, 150 2, 600 3, 100 4, 900 5, 600 5, 600 Tear resistance (dmfl) 44 22 29 Zero span tensile (m.) 5, 490 6, 560 7, 130

As shown by Table IV, calender roll temperatures of 250 F. or greater were efiective in increasing the strip tensile strength of non-woven mat I. The lack of decrease, indeed, even an increase, of zero span tensile strength at the highest calender roll temperature as well as at an intermediate temperature shows that suflicient pressure was applied to prevent shrinkage of the fibers of the mat. Also to be noticed is the decrease in tear resistance of the non-woven mat as the strip tensile strength is improved.

That the point-bonding technique is eifective to increase the strip tensile strength of other non-woven mats produced as non-woven mat I of example 21 is illustrated by Examples 22-28.

EXAMPLES 22-28 Various non-woven mats made under melt-blowing conditions which produce fibers that have a diameter between about 1 to 10 microns (see Table I) were pointbonded at elevated temperatures to fuse-bond the fibers of the mat. The fuse-bonding was accomplished with the press and plates of Examples 1-15. The plates were heated to the temperatures set forth in Table V. The fuse-bonding was carried out for 10 seconds, with the mats being closed to a spacing of 0.005 inch between the smooth-surfaced upper plate and the lands of the projections on the lower plate. Except for Example 26, two sheets of tissue paper were used between the nonwoven mats and the lower plate, and one sheet of foil was used between the non-woven mats and the upper plate. Example 26 had two sheets of foil between it and the lower plate and two sheets of foil between it and the upper plate. The point-bonded non-woven mats, as shown in Table V, exhibited high strip tensile strengths. The strip tensile strengths were greatly increased from the strip tensile strength of the untreated mat.

roll pressure was 700 p.l.i. and calender roll line speed The tear resistances of the as-made non-woven Mats M, P and Q, and the tear resistances of the treated nonwoven Mats P and Q of Examples 29 and 30 illustrate higher ranges of tear resistances which can be produced at tensile strengths less than about 2000 m.

As will now be apparent, the laminated nonwoven sheets of the present invention have structural properties making them well suited for applications requiring both high tensile strength and high tear resistance, such as heavy duty bags and shipping sacks, carpet backing, fabric backing and other liners and clothing components, synthetic paper, wrapping materials and the like.

Having fully and particularly described the non-woven sheet and the processes involved in this invention and having set out the best modes thereof, it will be appreciated that alterations and changes may be made by those skilled in the art which are nevertheless within the spirit and scope of the invention, as defined by the appended claims.

TABLE V Example Number 22 23 24 25 26 27 28 Mats B C D K M N 0 Press plate tern eratures:

Upper 280 290 280 275 260 275 280 Lower F.) 308 295 298 280 285 285 290 Fuse-bonded mat properties Strip tensile (m. 4, 849 5, 093 4, 975 4, 220 4, 180 4, 960 5, 720 Tear resistance (dmfl) 108 52 113 127 52 70 65 Together, Examples 21-28 illustrate some of the strip I claim:

tensile strengths which can be produced at tear resistances less than about 300 dm As evidenced by mats M, P and Q of Table I, meltblown non-woven mats can be produced which have high tear resistances but low strip tensile strengths. The highly tear resistant mats made under melt-blowing conditions which produce larger diameter fibers, such as Mats P and Q, can be treated to produce non-woven mats of increased strip tensile strengths while maintaining a high mat tear resistance. To do this, the mats are fuse-bonded either by calendering 0r point-bonding, at temperatures preferably no greater than 275 F., under pressures sufficient to prevent fiber shrinkage, as exemplified in Examples 29 and 30.

EXAMPLES 29-30 Samples of Mats P and Q were calendered at the temperatures and pressures set out in Table VI. Calender 1. A non-woven sheet of melt-blown thermoplastic fibcrs comprising:

a plurality of laminated non-woven mats of melt-blown thermoplastic fibers, at least one of said mats being comprised of fibers having diameters between 1-8 microns and having a strip tensile strength greater than 4000 m., and at least one other of said mats having a tear resistance greater than 400 dm.

2. A non-woven sheet according to claim 1 wherein said mats are mats of polypropylene fibers.

3. A non-woven sheet according to claim 2 in which the strip tensile strength of said one mat is greater than 5000 4. A non-woven sheet according to claim 2 in which the tear resistance of said other mat is greater than 1000 dmfi.

5. A non-Woven sheet according to claim 2 in which said mat (A) is self-bonded.

said mat (B) has fibers having a diameter greater than 10 microns.

8. A non-woven sheet according to claim 7 in which 5 said mat (B) has fibers within the range of 15 and 25 microns.

9. A non-woven sheet according to claim 2 wherein said mats are laminated by point welding.

10 10. A non-woven sheet according to claim 2 in which said mats are laminated by adhesive.

References Cited UNITED STATES'PATENTS 3,276,944 10/1966 Levy 161'-157 X 3,341,394 9/1967 Kinney 161150X 3,704,198 11/1972 Prentice 161150X GEORGE F. LESMES, Primary Examiner L. T. KENDELL, Assistant Examiner US. Cl. X.R. 

